Systems and Methods for Reducing Pipeline Erosion Using Acoustic Radiation

ABSTRACT

An acoustic brake system includes one or more transducers configured to couple to an external wall of a pipe. The one or more transducers are configured to generate a standing wave within the pipe. The standing wave comprises one or more nodes within the pipe. When a particulate-laden fluid flows through the pipe, a plurality of particulates move towards the nodes and away from a wall of the pipe. The acoustic brake system also includes a function generator electrically coupled to the one or more transducers and configured to drive the one or more transducers.

TECHNICAL FIELD

The present application relates to reducing pipeline erosion. Specifically, the present application relates to reducing pipeline erosion by slowing down erosion-causing particulates using acoustic radiation forces.

BACKGROUND

Production fluid that enters hydrocarbon production systems often contains an amount of particulates, such as sand particles, from surrounding formations. These particulates flow through the pipes and can impact or stick onto the walls of the pipes. This can contribute to erosion, wear, or damage of the pipes and other equipment. Indeed, erosion has been long recognized as a potential source of failure in oil and gas production systems. In particular, elbow and curved portions of piping are especially susceptible to erosion from particulates in the fluid flow due to the inertia effects of traveling particulates. However, detection of erosion as it progresses can be very difficult and plant operators rarely have an adequate measure of the internal conditions of the pipelines in their systems. This makes erosion management extremely tedious and sometimes impractical. Therefore, it is very important to develop new tools, efficient methods and advanced technologies to reduce erosion in pipes. Presently, some means of reducing erosion include reduction of the rate of fluid flow through production piping, which reduces the velocity of the particulates, or designing pipes that reduce flow velocity and minimize elbow or curved pipe portions. However, such techniques reduce the overall speed of production, which has financial implications and drawbacks. Another method is the use of sand screens or gravel packs to filter particulates out of the production stream. However, some particulates are so small that these particulates are able to travel through the sand screens, and generate a significant amount of erosion. Thus, existing techniques for reducing erosion due to particulates do not provide an adequate solution.

SUMMARY

In general, in one aspect, the disclosure relates to an acoustic brake system. The acoustic brake system includes one or more transducers configured to couple to an external wall of a pipe. The one or more transducers are configured to generate a standing wave within the pipe. The standing wave comprises one or more nodes within the pipe. When a particulate-laden fluid flows through the pipe, a plurality of particulates move towards the nodes and away from a wall of the pipe. The acoustic brake system also includes a function generator electrically coupled to the one or more transducers and configured to drive the one or more transducers.

In another aspect, the disclosure can generally relate to an acoustic brake system. The acoustic brake system includes one or more transducers coupled to an external wall of a pipe. The one or more transducers are configured to generate an ultrasonic field within the pipe such that when a particulate-laden fluid flows through the pipe, the ultrasonic field creates an acoustic radiation force on a plurality of particulates. The force pushes the plurality of particulates away from a wall of the pipe. The acoustic brake system also includes a function generator electrically coupled to the one or more transducers and configured to drive the one or more transducers.

In another aspect, the disclosure can generally relate to a method of reducing particulate impact in a pipe. The method includes coupling an acoustic brake system to an external wall of a pipe, the acoustic brake system comprising one or more transducers. The method further includes coupling the one or more transducers to the external wall of the pipe. The method also includes transmitting a signal from the function generator to the one or more transducers. The method further includes generating a standing wave within the pipe, the standing wave comprising one or more nodes. The method also includes pushing a plurality of particulates towards the one or more nodes and away from a wall of the pipe when a particulate-laden fluid flows through the pipe.

These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate only example embodiments of the present disclosure, and are therefore not to be considered limiting of its scope, as the disclosures herein may admit to other equally effective embodiments. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, reference numerals designate like or corresponding, but not necessarily identical, elements. In one or more embodiments, one or more of the features shown in each of the figures may be omitted, added, repeated, and/or substituted. Accordingly, embodiments of the present disclosure should not be limited to the specific arrangements of components shown in these figures.

FIG. 1 illustrates a schematic diagram of an example application of an acoustic brake system used in a downhole environment, in accordance with example embodiments of the present disclosure.

FIG. 2 illustrates a cross-sectional representation of a first example behavior of particulates in a pipe having an acoustic brake system disposed thereon, in accordance with example embodiments of the present disclosure.

FIG. 3 illustrates another cross-sectional representation of a second example behavior of particulates in a pipe having the acoustic brake system disposed thereon, in accordance with example embodiments of the present disclosure.

FIG. 4 illustrates the behavior of particulates as the particulates flow through a segment of pipe having the acoustic brake system disposed thereon, in accordance with example embodiments of the present disclosure.

FIG. 5 illustrates a cross-sectional view looking down a pipe showing a particulate-laden fluid within the pipe under influence of the acoustic brake system, in accordance with example embodiments of the present disclosure.

FIG. 6 illustrates an example configuration of an acoustic brake system, in which the acoustic brake system includes multiple transducers formed as rings around a pipe, in accordance with example embodiments of the present disclosure.

FIG. 7 illustrates another example embodiment of an acoustic brake system, in which the acoustic brake system includes a transducer strip disposed along a length of a segment of pipe, in accordance with example embodiments of the present disclosure.

FIG. 8 illustrates another example configuration of an acoustic brake system, in which the acoustic brake system includes a first transducer sheet and a second transducer sheet disposed around a pipe, in accordance with example embodiments of the present disclosure.

FIG. 9 is a flow chart illustrating a method of reducing particulate impact in a pipe, in accordance with example embodiments of the present disclosure.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Example embodiments directed to systems and methods for reducing pipeline erosion using acoustic radiation will now be described in detail with reference to the accompanying figures. Like, but not necessarily the same or identical, elements in the various figures are denoted by like reference numerals for consistency. In the following detailed description of the example embodiments, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure herein. However, it will be apparent to one of ordinary skill in the art that the example embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. The example embodiments illustrated herein include certain components that may be replaced by alternate or equivalent components in other example embodiments as will be apparent to one of ordinary skill in the art. Example embodiments discussed in the present disclosure are directed towards downhole production piping applications. Such examples are employed to exhibit features of the present disclosure in context, and not as a limitation on the application of the systems and methods of the present disclosure. In practice, the systems and techniques disclosed herein have applications in subterranean environments, underwater environments, and above-ground systems.

Referring now to the drawings, FIG. 1 illustrates an example application of an acoustic brake system 102. Specifically, FIG. 1 illustrates a schematic diagram of a well site 100 in which the acoustic brake system 102 is disposed on a production pipe 106, in accordance with example embodiments of the present disclosure. In certain example embodiments, a wellbore 108 is formed in a subterranean formation 118 and coupled to a rig 110 on a surface 112 of the formation 118. The formation 118 can include one or more of a number of formation types, including but not limited to shale, limestone, sandstone, clay, sand, and salt. The surface 112 may be ground level for an on-shore application or the sea floor for an off-shore application. In certain embodiments, a subterranean formation 118 can also include one or more reservoirs in which one or more resources (e.g., oil, gas, water, steam) are located. In certain example embodiments, the wellbore 108 is cased with cement or other casing material, which is perforated to allow fluids to flow from the formation 118 into the well 108. The production tubing 106 is disposed downhole within the well 108 and fluids enter the production tubing 106 from the well 108. Fluids are recovered and brought to the rig 110 through the production tubing 106. In certain example embodiments, a production packer 105 is coupled to the production tubing 106. Although FIG. 1 illustrates an example downhole application of an acoustic brake system 102, in practice, the acoustic brake system 102 can be used in surface or underwater applications as well, including but not limited to refinery pipe systems, flow loops, and the like.

The production fluid travelling through the production tubing 106 may contain particulates which can cause erosion and wear on the production tubing 106. In certain example embodiments, the acoustic brake system 102 is disposed in an annular space 114 around a portion of the production tubing 106. In certain such example embodiments, the acoustic brake system 102 is disposed around the production tubing 106 at an elbow 116 in the production tubing 106. The acoustic brake system 102 slows down and mildly suspends the particulates in the fluid as the fluid and particulates flow through the elbow 116 portion of the production tubing 106. This reduces the impact of the particulates onto the inner walls of the production tubing 106, which reduces erosion and wear on the production tubing 106. In certain example embodiments, the transducers can be disposed on portions of the production tubing 106 downstream of the elbow 116, which is also relatively susceptible to the impact of the traveling particulates. In other example embodiments, the acoustic brake system 102 and its transducers can be disposed on any portion of the production tubing 106. In certain example embodiments, transducers can be placed along the entire length of the production tubing 106, continuously or in segments. In certain example embodiments, the acoustic brake system 102 includes one or more transducers, which emit acoustic waves into the production tubing 106 to suspend the particulates, as is further described below with reference to FIGS. 2-4. The acoustic brake system 102 can also have a variety of configurations and positions, an example set of which is described below with reference to FIGS. 6-8.

FIG. 2 illustrates a cross-sectional representation 200 of a pipe 202 having an acoustic brake system 102 disposed thereon, in accordance with example embodiments of the present disclosure. Specifically, the acoustic brake system 102 includes a transducer 206 configured to generate a standing wave having a single node 204 within the pipe 202. In certain example embodiments, the standing wave has a frequency that matches one of the resonant frequencies of the pipe 202. In certain example embodiments, the transducer 206 is coupled non-intrusively to the pipe. Nodes refer to the points in the standing wave with the smallest amplitude. In certain example embodiments, the transducer 206 emits an acoustic wave from a first side 208 a of the pipe 202 which reflected back from a second side 208 b of the pipe 202, forming the standing wave. Particulates 210 in the fluid flowing through the pipe 202 are forced towards the node 204 and away from the walls of the pipe 202 as the particulates 210 flow past the acoustic brake system 102. In certain example embodiments, the node 204 represents a low pressure region within the pipe 202. In certain example embodiments, the travel velocity of the particulates 210 decreases when traveling through the standing wave. The particulates 210 go from being randomly scattered to gathering at the node 204. In certain example embodiments, the remaining fluid is unaffected by the standing wave and thus flows at the normal velocity. As such, the particulates 210 are slowed down without slowing down the speed of production or fluid recovery.

In certain example embodiments, the transducer 206 is coupled to a function generator 212, which outputs a signal to excite the transducer 206 and implement the standing wave within the pipe 202. In certain example embodiments, the transducer 206 is tuned to emit a frequency which matches one of the pipe's resonant frequencies. This ensures optimal ultrasound transmission through the pipe wall. The transmitted frequencies produce an ultrasonic field in the pipe 206, which creates an acoustic radiation force on the particulates in the flow. In certain example embodiments, this force keeps the particulates from impacting and/or sticking to the pipe wall where erosion might occur. In certain example embodiments, the force reduces the speed at which the particulates impact the pipe wall, which decreases the likelihood of adhesion to the pipe. Specifically, the acoustical radiation force pushes the particulates away from the pipe wall, gathering at the node 210 instead.

The function generator can be preprogrammed or controlled to output a signal that implements a standing wave having the parameters suitable for a specific application. For example, the amplitude, phase, and frequency of the signal generated by the function generator can be determined and set to implement a standing wave having such characteristics. In certain example embodiments, the one or more transducers are actuated through amplitude-modulation. In other example embodiments, the one or more transducers are actuated through frequency modulation.

FIG. 3 illustrates another cross-sectional representation 300 of a pipe 202 having the acoustic brake system 102 disposed thereon, in accordance with example embodiments of the present disclosure. Specifically, the acoustic brake system 102 of FIG. 3 includes a transducer 206 configured to generate a waveform forming two nodes 204 within the pipe 202. Thus, the particulates 210 gather at the two nodes 204 and away from the walls of the pipe 202. In such an example embodiment, the particulates 210 that flow through the standing wave are attracted towards the closest node 204. In certain example embodiments, the transducer 206 can be configured to generate a waveform forming any number of nodes 204 within the pipe 202, and positioned at various locations within the pipe 202. The number and location of the nodes 204 may be determined based on various factors, including the size of the pipe 202, speed of flow, and expected amount and size of particulates, among others. In certain example embodiments, a plurality of the one or more transducers 206 generate waveforms of the same frequency. In certain other example embodiments, a plurality of the one or more transducers 206 generate different frequencies. Generating different frequencies can help trap particulates of different sizes.

FIG. 4 illustrates the behavior of particulates 210 as the particulates 210 flow through a segment of pipe 202 having the acoustic brake system 102 disposed thereon, in accordance with example embodiments of the present disclosure. Reference number 402 refers to the initial behavior of particulates 210 as the particulates enter the segment of pipe in which the acoustic brake system 102 generates a standing wave. At this point, the particulates 210 are dispersed in the fluid in their natural state, with some particulates 210 touching or near the walls of the pipe 202.

Reference number 404 refers to the behavior of the particulates 210 quickly after the particulates 210 have entered the segment of pipe 202 having the standing wave, in which the particulates have begun to move towards the nodes 204 of the standing wave and away from the walls of the pipe. For example, in a certain application, the time is approximately 0.5 ms after the particulates 210 enter the segment of pipe 202. The timing parameter is provides as an illustration and for context only. In practice, the timing can vary depending on various parameters and conditions of the system.

Reference number 406 refers to the behavior of the particulates 210 after the particulates 210 have been in the segment of pipe 202 a period of time longer than that of 404. At this point, the particulates 210 have gathered at the nodes 210 and away from the walls of the pipe 202. For example, in a certain application, the time is approximately 5 ms after the particulates 210 enter the segment of pipe 202. As the particulates 210 flow through the remainder of the segment of pipe 202 having the acoustic brake system 102, the particulates 210 flow along the nodes 210 and away from the walls of the pipe 202 until the particulates 210 exit the segment of pipe 202 having the standing wave. In certain example embodiments, the acoustic brake system 102 is placed at elbow or curved portions of pipes as these regions are more susceptible to particulate impact due to the inertial effect on the particulates 210 at these points. In certain example embodiments, the acoustic brake system 102 can be placed anywhere on a pipe.

FIG. 5 illustrates a cross-sectional view looking down a pipe 502 in which the acoustic brake system 102 has generated a standing wave, in accordance with example embodiments of the present disclosure. The acoustic brake system 102 of FIG. 5 is configured to generate an acoustic waveform having five nodes 204, forming concentric circles in the pipe 502. FIG. 5 shows that the particulates 210 are concentrated at the five nodes 204 and away from the wall of the pipe 504.

FIG. 6 illustrates an example configuration 600 of an acoustic brake system 602, in which the acoustic brake system 602 includes multiple transducers 606 formed as rings around a pipe 604. In certain example embodiments, the transducers 606 are set at the same resonant frequency, and particulates in the fluid flowing through the pipe travel along the one or more nodes of the generated standing wave and away from the walls of the pipe 604. The transducer rings 606 can be of any size and there can be any number of rings. In certain example embodiments, the transducer rings 606 have a gap or disconnect in the ring 606. This space allows the transducer material to expand under high temperature conditions.

FIG. 7 illustrates another example embodiment 700 of an acoustic brake system 702, in which the acoustic brake system 702 includes a transducer strip 706 disposed along a length of a segment of pipe 704. In certain example embodiments, the acoustic brake system 702 includes a plurality of transducer strips 706 disposed along the length of pipe 704. The transducer strips 706 can be of any size and disposed on the pipe 704 in any configuration.

FIG. 8 illustrates another example configuration 600 of an acoustic brake system 802, in which the acoustic brake system 802 includes a first transducer sheet 806 a and a second transducer sheet 806 b disposed around a pipe 804. In certain example embodiments, the first transducer sheet 806 a is disposed on a first side of a segment of the pipe 804 and a second transducer sheet is disposed on a second side of the segment of the pipe 804. The transducer sheets 806 can be of any size and shape and cover all or a portion of the segment of pipe 804

An acoustic brake system 102 can have one or a plurality of separate transducers 206 disposed about a pipe in any configuration. Specifically, the transducers 206 can have any suitable shape, such as a ring, a strip, a spot, a sheet, and the like. Each transducer 206 in an acoustic brake system 102 can generate the same or distinct waveforms. The desired pattern or configuration of nodes 204 within the pipe 202 can be implemented by configuring the waveforms generated by the transducers 206 through the function generator 212. The transducers 206 are coupled to and driven by the function generator 212. In certain example embodiments, the function generator 212 is coupled to the pipe 202 as well or at a nearby location. In certain example embodiments, the function generator 212 is preprogrammed to generate a specified signal and waveform. In certain example embodiments, the function generator 212 is controllable through a wired or wireless controller, which can set or change the parameters of the signal generated by the function generator. In certain example embodiments, the frequency generator is powered by an attached or remote power source. In certain example embodiments, in order to reduce heating of the transducer 206, the transducers 206 are configured to emit in tone-burst mode, swept frequency, or through amplitude modulation. In certain example embodiments, wetted transducers, which are in direct contact with the fluid within the pipe 202 are used. In certain example embodiments, the transducers 202 are disposed inside the pipe 202 rather than outside of the pipe.

FIG. 9 illustrates a method 900 of reducing particulate impact in a pipe, in accordance with example embodiments of the present disclosure. In certain example embodiments, the method 900 includes coupling an acoustic brake system to an external wall of a pipe (step 902). In certain example embodiments, the acoustic brake system includes one or more transducers. In certain example embodiments, the acoustic brake system also includes a function generator coupled to the one or more transducers. In certain example embodiments, the method 900 further includes coupling the one or more transducers to the external wall of the pipe (step 904). The one or more transducers can have any shape, size, or configuration that is suitable for the pipe and the desired effect. The method further includes transmitting a signal from the function generator to the one or more transducers (step 906). The method further includes generating a standing wave within the pipe by the one or more transducers, in which the standing wave includes one or more nodes (step 908). The method also includes pushing a plurality of particulates towards the one or more nodes and away from the walls of the pipe (step 910). In certain example embodiments, the standing wave creates one or more relatively high and one or more relatively low pressure regions, in which the relatively low pressure regions are away from the walls of the pipe. Thus, the particulates are attracted towards the low pressure regions.

Although embodiments described herein are made with reference to example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope and spirit of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein. 

What is claimed is:
 1. An acoustic brake system, comprising: one or more transducers configured to couple to an external wall of a pipe, wherein the one or more transducers generate an acoustic standing wave within the pipe, the acoustic standing wave comprising one or more nodes within the pipe, wherein when a particulate-laden fluid flows through the pipe, a plurality of particulates move towards the nodes and away from a wall of the pipe; and a function generator electrically coupled to the one or more transducers and configured to drive the one or more transducers.
 2. The acoustic brake system of claim 1, wherein the waveform matches a resonant frequency of the pipe.
 3. The acoustic brake system of claim 1, wherein the one or more transducers has ring shape, a strip shape, a sheet shape, a spot shape, or any combination thereof.
 4. The acoustic brake system of claim 1, where a plurality of transducers are configured to generate waveforms of the same frequency.
 5. The acoustic brake system of claim 1, wherein a plurality of transducers are configured to generate waveforms of one or more different frequencies.
 6. The acoustic brake system of claim 1, wherein the acoustic standing wave creates one or more relatively high and relatively low pressure regions, wherein the one or more low pressure regions are away from the wall of the pipe, and wherein the plurality of particulates gather at or near the one or more low pressure regions.
 7. The acoustic brake system of claim 1, wherein the acoustic standing wave creates an ultrasonic field within the pipe, wherein when the particulate-laden fluid flows through the pipe, the ultrasonic field creates an acoustic radiation force on a plurality of particulates which slows down the speed of the plurality of particulates and pushes the plurality of particulates away from the wall of the pipe.
 8. An acoustic brake system, comprising: one or more transducers coupled to a wall of a pipe, the one or more transducers configured to generate an ultrasonic field within the pipe, wherein when a particulate-laden fluid flows through the pipe, the ultrasonic field creates an acoustic radiation force on a plurality of particulates which pushes the plurality of particulates away from a wall of the pipe; and a function generator electrically coupled to the one or more transducers and configured to drive the one or more transducers.
 9. The acoustic brake system of claim 8, wherein the one or more transducers form one or more rings around the pipe.
 10. The acoustic brake system of claim 8, wherein the ultrasonic field creates one or more relatively high and relatively low pressure regions, wherein the one or more low pressure regions are away from the wall of the pipe, and wherein the plurality of particulates gather at or near the one or more low pressure regions.
 11. The acoustic brake system of claim 8, wherein the one or more transducers are disposed on or adjacent to a curved portion of the pipe.
 12. The acoustic brake system of claim 8, wherein the ultrasonic field has a waveform which matches a resonant frequency of the pipe.
 13. The acoustic brake system of claim 8, wherein the one or more transducers are disposed on an external wall of the pipe.
 14. The acoustic break system of claim 8, wherein the one or more transducers are actuated in a burst-mode.
 15. The acoustic break system of claim 8 wherein the one or more transducers are actuated continuously.
 16. The acoustic break system of claim 8 wherein the one or more transducers are actuated through amplitude-modulation.
 17. The acoustic break system of claim 8 wherein the one or more transducers are actuated through frequency modulation.
 18. The acoustic break system of claim 8, wherein the one or more transducers are disposed within the pipe.
 19. A method of reducing particulate impact in a pipe, comprising: coupling an acoustic brake system to an external wall of a pipe, the acoustic brake system comprising one or more transducers; coupling the one or more transducers to the external wall of the pipe; transmitting a signal from the function generator to the one or more transducers; generating a standing wave within the pipe, the standing wave comprising one or more nodes; and pushing a plurality of particulates towards the one or more nodes and away from a wall of the pipe when a particulate-laden fluid flows through the pipe.
 20. The method of claim 19, comprising: generating an ultrasonic field within the pipe; creating one or more relatively high and relatively low pressure regions, wherein the one or more low pressure regions are away from the wall of the pipe, and forcing the plurality of particulates towards the one or more low pressure regions.
 21. The method of claim 19, wherein the standing wave matches a resonant frequency of the pipe.
 22. The method of claim 19, where a plurality of the one or more transducers are configured to generate waveforms of the same frequency or of one or more different frequencies. 